EnerSys PowerSafe m Series Battery Safety, Installation, Storage, Operating And Maintenance Manual Download Page 1

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Summary of Contents for PowerSafe m Series

Page 2: ...ated lead acid batteries as well as certain installation considerations Failure to observe the precautions as presented may result in injury or loss of life 2017 by EnerSys All rights reserved This document is proprietary to EnerSys This document cannot be copied or reproduced in whole or in part without the express written permission of EnerSys Please check our website for literature updates www ...

Page 3: ...tially hazardous situations and conditions which if not avoided may result in injury Equipment damage may also occur Other warning symbols may appear along with the Danger and Caution symbol and are used to specify special hazards These warnings describe particular areas where special care and or procedures are required in order to prevent serious injury and possible death The electrical warning s...

Page 4: ...ently grounded remove source of ground Contact with any part of a grounded battery can result in electrical shock The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance 7 Verify circuit polarities before making connections 8 Disconnect charging source and load before connecting or disconnecting terminals 9 Valve regulated lead acid VRLA batteri...

Page 5: ...so be toxic This unit contains sealed lead acid batteries Lack of preventative maintenance could result in batteries exploding and emitting gasses and or flame An authorized trained technician must perform annual preventative maintenance Failure to replace a battery before it reaches end of life may cause the case to crack possibly releasing electrolyte from inside the battery and resulting in sec...

Page 6: ...xternal Damage 7 3 3 Concealed Damage 8 4 0 BATTERY STORAGE BEFORE INSTALLATION 9 4 1 General 9 4 2 Storage Location 9 4 3 Advance Preparation 10 5 0 INSTALLATION CONSIDERATIONS 11 5 1 General 11 5 2 Considerations for Connecting the Battery System to Operating Equipment 12 5 3 Considerations for Parallel Installation 13 6 0 UNPACKING AND HANDLING FOR INSTALLATION 14 6 1 General 14 6 2 Accessories...

Page 7: ... 28 16 0 INITIAL and or FRESHENING CHARGE 29 17 0 OPERATION 30 17 1 General 30 17 1 1 Determining the State of Charge 30 17 2 Float Operation 31 17 2 1 Float Charge Method 32 17 3 Equalizing Charge 33 17 3 1 Equalizing Charge Method 34 18 0 BATTERY TAPS 35 19 0 PILOT CELL 35 20 0 MAINTENANCE 35 20 1 Battery Cleaning 35 20 1 1 Standard Cleaning 35 20 1 2 Mild Corrosion Cleaning 36 20 1 3 Terminal R...

Page 8: ...ents in conjunction with superior and uniform thermal management reduce the chances of thermal runaway Temperature compensation chargers are also recommended PowerSafe VRLA batteries typically do not require a seperate battery room or Hood exhaust system like traditional Vented Lead Acid VLA Batteries However they do require adequate ventilation and should not be placed in air tight locations Syst...

Page 9: ...all the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service Also refer to all applicable federal state and local regulations and industry standards YOU SHOULD BE TRAINED IN HANDLING INSTALLING OPERATING AND MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM 1 3 Service Should you require installation supervision service parts accessories or ...

Page 10: ...U SHOULD BE TRAINED IN HANDLING INSTALLING OPERATING AND MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM You MUST understand the risk of working with batteries and BE PREPARED and EQUIPPED to take the necessary safety precautions If not contact EnerSys Reserve Power Service 2 2 Safety Equipment and Clothing When working with any battery system be sure you have the necessary tools and s...

Page 11: ...the area THOROUGHLY with WATER 3 Get MEDICAL ATTENTION if required In case of EYE CONTACT with sulfuric acid IMMEDIATELY 1 FLUSH THOROUGHLY for at least 15 minutes with large amounts of WATER 2 Get MEDICAL ATTENTION In case of sulfuric acid CONTACT WITH CLOTHING OR MATERIAL IMMEDIATELY 1 REMOVE contaminated CLOTHING 2 Apply a solution of sodium bicarbonate solution 1 0lb 1 0gal or 0 5 kg 5 0 liter...

Page 12: ...sure self contained breathing apparatus Wear acid resistant clothing Water applied to electrolyte generates heat and causes it to splatter TOXIC FUMES Burning plastic may cause toxic fumes Leave area as soon as possible if toxic fumes are present Wear breathing apparatus if required to remain in the area 2 3 3 Electrical Shocks and Burns Multi cell battery systems can attain high voltage and or cu...

Page 13: ...velops within the system an increased shock hazard exists between the terminal of opposite polarity and ground 2 If a second unintentional ground develops within the already unintentionally grounded system a short circuit may occur and cause explosion or fire Therefore should you be required to work on a grounded battery system make absolutely sure you use the correct safety precautions equipment ...

Page 14: ...carrier representative is still on site inventory all materials against the Bill of Lading and inspect for visible external damage Check material quantities received against the Bill of Lading including the number of battery pallets and the number of accessory boxes Note any damage to packing material and or product wetness or stains indicating electrolyte leakage If damage is noted 1 Make a descr...

Page 15: ... against the detailed packing list to verify receipt of all materials in the quantities specified For export the cells may be packed in wooden boxes which must be opened completely and carefully and the cells then handled as described hereafter See Section 6 for unpacking and handling DELAY IN NOTIFYING THE CARRIER MAY RESULT IN LOSS OF YOUR RIGHT TO REIMBURSEMENT FOR DAMAGES Refer to the Bill of ...

Page 16: ...RAGE BEFORE INSTALLATION TABLE 4 1 STORAGE TEMPERATURE STORAGE TIME 32 F 0 C to 50 F 10 C 9 months 51 F 11 C to 77 F 25 C 6 months 78 F 26 C to 92 F 33 C 3 months If storage time exceeds the storage time recommended in Table 4 1 give the battery a freshening charge before the end of the recommended storage interval See Section 16 for charging information PowerSafe VRLA mP Series batteries must be ...

Page 17: ...ailable with an appropriate AC supply voltage The positioning of the cells to accept temporary inter cell connectors is another consideration for advanced planning Make every effort to get the battery connected to the charger before expiration of the storage period thereby avoiding the additional labor cost of freshening charges WARNING Failure to charge as noted voids the battery s warranty ...

Page 18: ...oor anchoring Table 5 1 will assist you to ensure that all requirements for installation location are considered Space Aisle space should be in accordance with the National Electric Code NEC Article 110 16 or local codes Clearance from wall equipment 4 10 cm minimum Environment Clean cool and dry The location should be selected to keep water sunlight oil and dirt away from all cells Temperature Am...

Page 19: ...ry room or hood exhaust is required However VRLA batteries do require adequate ventilation and should not be installed in air tight locations Grounding It is recommended that the modules or racks be grounded in accordance with NEC and or local codes Floor Reasonably level Shimming up to 1 4 6mm maximum to level battery front to rear and side to side Capable of supporting the weight of the battery ...

Page 20: ...t as determined by the equipment system supplier Excessive voltage drop will reduce the desired support time of the battery system 5 3 Considerations for Parallel Installation If it is necessary to connect the battery system in parallel to obtain sufficient capacity cable connections to each of the parallel strings are important To obtain proper load sharing on the discharge satisfactory recharge ...

Page 21: ...umber may also be beneficial when using belts to install a cell as this will provide space to pass the belt under the product Terminal caps must be in place during product installation DO NOT attempt to remove the pressure relief valves or vent covers as this will void the warranty Attempted removal of the valve may also damage the vent and prevent proper functioning of the battery DO NOT attempt ...

Page 22: ...ft Crane Cell Lift Cart Chalk Line Torpedo Level Plastic Torque Wrench 10 200 in lbs Torque Wrench 50 100 ft lbs Floor Anchors User supplied per battery system and stress analysis Floor Shims User supplied 3 8 Drive Rachet Insulated Wrench with Minimum 3 Extension with 5 16 thru 3 4 Sockets Insulated Box Wrenches 5 8 thru 3 4 Screwdrivers Wipes Paper or Cloth Stiff Bristle Nonmetallic Brush Pad Ta...

Page 23: ...em layout available floor space including aisles for installation maintenance and possible cell replacement Review the installation considerations of this manual Section 5 0 The recommended clearance between these racks and any objects including walls and equipment is 4 inches 102 mm NOTE Floor anchoring is REQUIRED for all installations Floor anchors are not provided Allow sufficient clearance be...

Page 24: ...8 50 98 38 98 41 98 50 98 35 5 50 8 68 5 50 8 58 4 83 8 99 0 106 6 129 5 83 8 99 0 106 6 129 5 99 0 106 6 129 5 21 49 30 49 40 97 30 49 34 99 N A N A N A N A N A N A N A N A N A N A N A 54 6 77 4 104 1 77 4 88 9 N A N A N A N A N A N A N A N A N A N A N A 10 2 cm 4 00 in TYP L 20 3 cm 2 x L 8 00 in 10 2 cm 4 00 in TYP L 10 2 cm 4 00 in TYP L 4 00 in 10 2 cm L 10 2 cm 4 00 in TYP 10 2 cm 4 00 in TY...

Page 25: ... bolts until frame assembly is complete 2 Install ALL base beams before continuing 8 2 Frame Module Weldment 1 Install frame module weldment on top of base beams See Figure 5 2 Bolt frame module weldment to base beams Refer to below list for hardware order and Figure 5a Hex Bolt M12x1 75 40mm Lock Washer Frame Module Weldment Base Beam Flat Washer Hex Nut 3 Torque all module connections except anc...

Page 26: ...s CAUTION USE CAUTION WHEN HANDLING THE PowerSafe mP Series Cells After a cell has been inserted into a metal can at the factory a loose fit could develop because of recombination The cell could slip very easily from the metal can if the cell is turned so that the open end of the metal can is lower than the closed end of the metal can Serious personal injury could result if the cell unintentionall...

Page 27: ...viously placed cell module Refer to the Assembly Drawing for the cell polarity configuration See Figure 6 9 Leave safety caps on terminals until connections are ready to be made 9 1 Module Retainers 1 For each cell module install retainer plates using a M10x1 5 25mm Serrated Hex Bolt See Figure 7 The middle rows use a flat retainer the top and bottom rows use a retainer with a formed edge See Figu...

Page 28: ...FIGURE 10 4 Install next empty frame module weldment as described in Section 8 2 See Figure 8 and 8a Torque bolts to 75 ft lbs 5 Install cell modules and retainer plates as described in Section 9 0 9 1 See Figures 9 10 11 FIGURE 8a Upper Frame Module Weldment Lower Frame Module Weldment ...

Page 29: ...tall the top module weldment See Figure 12 1 Bolt top module weldment to frame module Refer to below list for hardware order and Figure 12a Hex bolt M12x1 75 40mm Lock washer Top module weldment Frame module weldment Flat washer Hex nut 2 Install top row of retainer plates as described in Section 9 1 See Figure 13 10 0 TOP MODULE WELDMENT FIGURE 12a Top Module Weldment Frame Module Weldment ...

Page 30: ...ll terminal Top termination is standard side termination is optional 1 Clean the terminal plate electrical contact areas with a stiff bristle nonmetallic brush pad until the surface is bright 2 Assemble and install the terminal plate assembly finger tight as shown in Figure 15 15a 16 16a 3 Torque all bolts to 15 ft lbs Hand tighten red insulators cherries FIGURE 15 FIGURE 15a FIGURE 16a FIGURE 16 ...

Page 31: ...ost a Hex Bolt b Flat Washer c Inter cell Connector d Battery Terminal e Inter cell Connector f Flat Washer g Lock Washer h Hex Nut 3 Bolt all inter cell connectors according to the ASSEMBLY DRAWING Assemble as the example shown in Figure 17 and below list CAUTION Tin plated parts do not require plating removal to provide an adequate contact surface only foreign material removal Very light brushin...

Page 32: ...NO OX ID grease to the terminal bar contact area 4 Install terminal bar as described in Section 13 1 and as shown in Figure 18a CAUTION Tin plated parts do not require plating removal to provide an adequate contact surface only foreign material removal Very light brushing and cleaning with a cloth is generally sufficient Lead Plated Parts Be careful not to remove the lead plating with excessive br...

Page 33: ...em as shown in Figure 18c 7 Bolt lower terminal bars to the cell terminals before attaching cable s Attach cable s to the terminal bars as shown in Figure 18d 8 For the final system connection bolt the L Bracket to the terminal plate as shown in Figure 18e 9 Torque bolts to 85 in lbs CAUTION Extreme care should be taken when connecting cables to the system Inadvertent contact of the cable ends wit...

Page 34: ...EnerSys sales service representative or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service 4 Make a copy of the Battery Maintenance Report found in the Safety Storage Operating and Maintenance Manual Measure and record the connection resistance of CELL to CELL and TABLE 14 1 APPROXIMATE VOLTAGE Number of Cells 12 24 2 15 x number of cells 2...

Page 35: ...ice or maintenance 15 1 Terminal Plate Covers 1 Install terminal plate covers as shown in Figure 19a Use hardware that is identified on the Assembly drawing located in the terminal plate box included with your shipment 2 An optional standoff is included in the terminal plate assembly kit in case additional space is needed between terminal plate and its cover 15 2 Safety Shields 1 Install ALL safet...

Page 36: ... cell that may be used for the initial charge Do NOT exceed 2 35 volts per cell Table 16 1 lists recommended initial charge voltages per cell and charge time for the initial charge Select the HIGHEST voltage the system allows for the initial charge without exceeding 2 35 volts per cell TABLE 16 1 CELL VOLTS Initial Charge 2 27 60 120 240 2 30 48 96 192 2 32 24 48 96 2 35 12 24 48 TIME Hours Temp 6...

Page 37: ...llowing method can be used to determine the state of charge of the battery 1 Place the battery on charge recharge following a discharge Read the ammeter The charging current will be a combination of the load current plus the current necessary to charge the battery 2 The battery becomes fully charged when the current to the battery starts to decrease and stabilize 3 When the current level remains c...

Page 38: ...pensated charger with adjustment as stated in Table 17 1 If a temperature compensated charger is not used manual adjustments must be made according to Table 17 1 TABLE 17 1 AVERAGE AMBIENT TEMPERATURE RECOMMENDED FLOAT VOLTAGE F C VOLTS PER CELL 25 4 2 33 35 2 2 33 45 7 2 32 55 13 2 30 65 18 2 28 77 25 2 25 85 29 2 23 95 35 2 21 105 41 2 19 115 46 2 17 125 52 2 17 Float voltage sustains the batter...

Page 39: ...ceed the maximum voltage for the connected load 2 Adjust the charger to provide the recommended float voltage at the battery terminals Do NOT use float voltages HIGHER or LOWER than those recommended Otherwise reduced battery life or reduced capacity will result 3 Check and record battery terminal voltage monthly for accurate calibration 4 If the VOLTS PER CELL average voltage is above or below th...

Page 40: ...ection of too low a float voltage variations in cell temperatures in the series at a given time due to environmental conditions or module arrangement The maximum cell to cell temperature difference is 5 F 3 C If cell temperature is the problem review the location instructions in Section 5 0 to ensure proper location of the battery system An equalizing charge should be given when the float voltage ...

Page 41: ...stem equipment 2 Divide this voltage by the number of cells connected in a series This is the MAXIMUM VOLTS PER CELL to be used for the equalizing charge This number should NOT exceed 2 35 VOLTS PER CELL average 3 Use Table 17 2 to determine the equalize charge time The times listed are the number of hours to charge the battery system AFTER the charge current has been stabilized for three hours St...

Page 42: ...battery with regard to voltage and temperature Designate as the pilot cell the cell with the lowest cell voltage in the series string following the initial charge Pilot cell readings serve as an interim indicator between regularly scheduled voltage readings of the complete battery The temperature sensor should be connected to the negative post of the pilot cell Read and record the pilot cell volta...

Page 43: ... the cell posts and connectors to neutralize the corrosion as described in Section 20 1 2 5 Clean the contact surfaces by rubbing the surface of post or terminal and lead plated or tin plated contact surfaces with a stiff bristle nonmetallic brush scotch brite type pad Lightly brush tin plated connectors Exercise care so you do NOT remove the plating on the connectors terminal plates or lugs expos...

Page 44: ... operation is essential for obtaining satisfactory performance Good records will show when corrective action may be required to eliminate possible charging maintenance or environmental problems Should you have ANY questions concerning how to perform the required maintenance contact your nearest EnerSys sales service representative or call the corporate office number listed on the back of this manu...

Page 45: ...any warranty claim made on the battery For system protection and to suit local conditions requirements more frequent readings quarterly are desirable Sample record charts are provided on the following pages Make a copy of the chart to use for your permanent records NOTE Some internal failure modes of cell type mP Series cannot be detected by cell or unit voltage measurements IEEE 1188 recommends t...

Page 46: ...BATTERY MAINTENANCE REPORT DDm DDS DDV DGX mSeries and mP Series ...

Page 47: ...BATTERY MAINTENANCE REPORT DDm DDS DDV DGX mSeries and mP Series ...

Page 48: ...tion No US MP OM 001 March 2017 21 0 CELL READING The square post terminal on this product allows for direct access to the terminal when taking cell readings The diagrams below are meant as a reference guide when taking readings ...

Page 49: ...shed by applying a freshening or equalization charge as described in Section 16 2 After the charge open the connections at the battery terminals to remove load from the battery 3 Throughout the extended non use period give the battery a recharge per the recommendations noted in Section 4 2 Disconnect the battery from the charger between charges 22 2 Return to Service To return the battery to norma...

Page 50: ...ture to exceed 105 F during charging 7 Do not clean cell with anything other than water bicarbonate of soda 8 Do not over torque connections 9 Do not store VRLA type batteries for over six months without charge at normal temperatures These are only a few of the precautions Please read all accompanying literature thoroughly for specific safety and installation information www enersys com 2017 EnerS...

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